STR 6670 KVA Oil Filled Transformer For AC Locomotive

RDSO//2008/EL/SPEC/0072
Page 1 of 27 Issued on 08.08.2008

(Rev. ‘0’) dt. 30.07.2008
SPECIFICATION NO. RDSO/2008/EL/SPEC/0072 (Rev. ‘0’) dt. 30.07.2008
l R; es
o t ; rs
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION
FOR
6670 KVA TRANSFORMER with HOTEL LOAD
FOR WAP4, 25 KV AC LOCOMOTIVE
SPECIFICATION NO. RDSO/2008/EL/SPEC/0072 (Rev. ‘0’)
Aug, 2008
ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011
(Rev. ‘0’) dt. 30.07.2008
Index
1.0 Background
2.0 Scope
3.0 Climate & Environment Conditions
4.0 Standards
5.0 Technical Data
6.0 General Design and Constructional aspects
7.0 Tests
8.0 Technical Documents to be supplied by the Supplier
9.0 Quality Assurance
Annexure - A – (TECTNICAL DATA TO BE SUPPLIED WITH THE OFFER)
Annexure – B (ADDITIONAL DATA TO BE SUBMITTED BY THE CONTRACTOR)
Annexure – C (TECHNICAL DATA OF EXISTING EQUIPMENTS IN USE)

(Rev. ‘0’) dt. 30.07.2008
Specification for 5400 KVA Transformer with

1000 KVA Hotel Load for WAP4 Locomotive
1.0 Background
IR have been using 5400 kVA Traction Transformer for WAP4/WAG7 electric
locomotives over the past several years for hauling prestigious passenger/freight
trains. In the present system, WAP4 locos hauling passenger trains utilize the
traction power solely for the hauling purposes whereas the power requirement for
the coaches of the train are met either through Self Generating (SG) System with
alternators/battery in individual coaches or the End-on-Generator (EOG) System
with the help of power cars at either end of the train as in the case of Rajdhani/
Shatabdi Express trains. With the advancement of technology and with the
objective of modernizing its coaching trains requirement in line with the trend
world over, Indian Railways have planned to switchover to Head on Generation
(HOG) System of passenger train operation where the power and air conditioning
requirements of different types of coaches in passenger trains is to be met from
the power of the locomotive hauling the train. This has necessitated the
development of a traction transformer with capacity suitable for traction as well
as power for the coaches henceforth termed as "hotel load" requirements.
2.0 Scope
The scope of this specification is to design, develop, manufacture and supply
traction transformer with hotel load power of 1000 kVA in addition to its present
capacity of (5400 + 270) kVA transformer used on WAP4 locomotives within the
same dimensional envelops of the existing transformer in view of the limitations
of space. The new transformer shall be designed using the modern insulation
scheme/materials and core design techniques to ensure the availability of
desired power in the specified space.
3.0 Climate & Environment Conditions
Atmospheric Metallic surface temperature under Sun: 75o C max. and in

temperature shade: 55o C max.
Minimum temperature: - 10 °C (Also snow fall in certain
areas during winter season)
Humidity 100% saturation during rainy season.
Reference site i) Ambient Temp.: 50o C
conditions
ii) Humidity: 100%
iii) Altitude: 1776 m above mean sea level.
Rain fall Very heavy in certain areas. The locomotive shall be
designed to permit its running at 10 kmph in flood water
(Rev. ‘0’) dt. 30.07.2008
level of 102 mm above rail level.

Atmosphere Extremely dusty and desert terrain in certain areas. The
during hot dust concentration in air may reach a high value of 1.6
weather mg/m3. In many iron ore and coalmine areas, the dust
concentration is very high affecting the filter and air
ventilation system.
Coastal area Locomotive and equipment shall be designed to work in
coastal areas in humid and salt laden atmosphere with
maximum pH value of 8.5, sulphate of 7 mg per litre, max.
concentration of chlorine 6 mg per liters and maximum
conductivity of 130 micro siemens /cm
Vibration The equipment sub-system and their mounting
arrangement will be designed to withstand vibrations and
shocks encountered in service as per IEC : 61373 unless
otherwise prescribed.
Electromagnetic High degree of electromagnetic pollution is anticipated in
Pollution locomotive machine room, where the equipment will be
mounted. Necessary precaution should be taken in this
regard.
Wind speed High wind speed in certain areas, with wind pressure
reaching 150 kg/m2
4.0 Standards
The following specifications shall generally be followed for manufacture and
testing of the transformer:-
• IEC-60310 - Rules for traction transformers and

reactors
• IEC-60076 - Recommendations for power transformers
• IEC-60077 - Rules for Electrical Traction Devices
• IEC-61373 - Vibration & shock
• IEC-60038 - Standard voltages
• IEC-60296 - Transformer Oil
IS- 12463
5.0 TECHNICAL DATA

(i) Rated Primary Current:
- Nominal - 25 KV
- Maximum - 27.5 KV
- Minimum - 19 KV
- Short Time-
Minimum - 17.5 KV
Maximum - 30 KV for short duration
(Rev. ‘0’) dt. 30.07.2008
(ii) Minimum Primary voltage for

guaranteed traction - 22.5 KV
(iii) Minimum voltage for functioning

of auxiliaries - 17.5 KV
(iv) Frequency - 50 Hz ± 3%
(v) No. of traction winding - Two
(vi) System of connection - One winding for each

of traction windings rectifier bridges.
(vii)
(a) Traction Winding rating - Rated no load voltage
of each traction winding
at 32nd tap and 22.5 KV
shall be 1000 Vrms
(approx. to suit rated
traction motor voltage
of 750 V on full load).
(b) Rated continuous current of each - 2700 A(approx.)

Traction winding at 22.5 KV
Corresponding to traction motor
Current of 3 x 900 Amps (DC)
(c) Apparent continuous power - 2700 x 1000

Of each winding 1000
= 2700 KVA
(d) Total continuous apparent - 2 x 2700 KVA

traction power at 22.5 KV = 5400 KVA
(e) Percentage Impedance - 10% ± variation as per

IEC: 60310
(f) The No load voltages at different taps from 0 to 32 notch

corresponding to 22.5KV shall be as under:
Tap Position Secondary voltage at traction

Winding at no load corresponding
to 22.5 KV
_________ __________________________
0 0
1 31
2 62
3 94
(Rev. ‘0’) dt. 30.07.2008
4 125
5 146
6 166
7 187
8 208
9 239
10 271
11 302
12 333
13 364
14 397
15 428
16 459
17 490
18 521
19 552
20 584
21 615
22 645
23 687
24 728
25 771
26 813
27 844
28 875
29 906
30 938
31 969
32 1000
(viii) Emergency Operation - In the event of failure of

cooling system i.e. oil
circulating pumps and
radiator blower with the
transformer shall be able to
deliver 50% of traction current
for ½ hr after having worked at
90% of the full load before
failure.
(ix) Percentage overload - 60% for two minutes followed

Rating after running by 50% for 10 minutes
continuously
at 90% full load
(x) Special duty
After continuous working at 90% full load, 1.7 times the rated current of
traction motors(900A) for 15 seconds repeated four times at 5 minutes
(Rev. ‘0’) dt. 30.07.2008
interval to match with the requirement of traction motor as per clause 37.2
of IEC 60349.
(xi) Auxiliary Winding
a) No. of windings - One
b) Rated voltage at - 830 V

22.5 KV
c) Continuous rated - 270 KVA

apparent power of
aux. windings.
d) % age Impedance - 3 to 5 %
e) Type of Loads - Single phase to three phase

static converter and single
phase loads like
battery charger, head light,
heaters etc.
(xii) Hotel Load Winding

22.5 KV

apparent power of
windings.

static converter.
(xiii) Alternatively in place of (xi) & (xii) above and as described at clause 6.2,
the KVA rating of auxiliary winding as well as hotel load winding may be
merged as single winding termed as Tertiary winding as per details given
below:

22.5 KV
(Rev. ‘0’) dt. 30.07.2008

apparent power of
windings.

arno convertor, Single phase to three
phase static converter.
(xiv) Rated primary power of - (5400 + 270 + 1000) KVA

The transformer = 6670 KVA
(xv) Cooling - Oil forced air forced
(xvi) Temperature rise limits - For class ‘H’ insulation for

copper conductor and mineral
insulating oil as cooling medium
(IEC 60310-20 ºC)
Winding - 55 ºC
Mineral oil - 45 ºC
(xvii) Insulation - Class ‘H’ with mineral insulating

oil alternatively any superior
insulation scheme may be
adopted. However for the
same, firm should indicate
it’s service experience,
advantages, size, weight and
cost implication etc
(xviii) Core - Latest core design with minimum core

loss
(xix) Cooling medium - Inhibited Transformer Oil

to IEC- 60296 / IS 12463(latest )
6.0 General Design and Constructional aspects:

6.1 The transformer block cell consists of following equipment.
i) Main transformer consisting of
a) An auto transformer winding.
b) A fixed ratio transformer with twin secondary winding for
feeding power to traction motors.
c) A tertiary winding for power supply to auxiliary machines.
(Rev. ‘0’) dt. 30.07.2008
d) Hotel load winding for meeting hotel load power

requirements.
e) A tank filled with mineral oil as coolant provided with

conservator.
ii) L.V. and H.V. bushings including 25 KV vertical take off type cable Head
Termination assembly.
iii) Cooling equipment comprising of a oil pump, a radiator and a motor blower
set.
iv) The tenderer shall give a detailed list of accessories required to make the
equipment offered including any other equipment not indicated in the
specification but considered necessary by the tenderer for improving the
performance of the transformer.
6.2 In order to accommodate the desired power of hotel load within the same
dimension of existing 5400 KVA transformer, the tenderer shall explore the
possibility of merging the auxiliary load(270 KVA) and hotel load(1000 KVA) in
the same winding giving 1270 KVA power at 750 V as indicated at Clause
5(Xiii)
6.3 The space available in the locomotive for accommodating transformer and the
associated equipment is given in the Drg. No. CLW/ES/SK-2/T22. The design
of the equipment shall be such as to ensure that the limiting dimensions are not
infringed. The mounting arrangement of the transformer shall be same as
shown in the drawing. The size of the opening in the under frame is 1400 x
2130 mm. The size of the tank should be 1375 x 2080 mm so as to ensure a
total clearance of 25 mm widthwise and 50 mm lengthwise. The top cover of
the tank should be so designed as to have the same configuration, for bushings
as per existing 5400 KVA transformer with separated provision for hotel load
winding bushings.
6.4 The equipment (including components and accessories and their mounting
arrangement shall generally conform to IEC 60076, IEC 60077-1&2 and
IEC 60310. It shall be of robust design suitable for traction duty and shall
withstand satisfactorily the vibration & shock as stipulated in the IEC:60310.
6.5 The auto transformer shall have 32 tapings for connection to the tap
changer. The transformer tank shall have provision for fitting an N-32 tap
changer of BT/Ganz type (mounting details of the tap changer to the
transformer shall be furnished to the successful tenderer).
6.6 The tenderer may offer class H Insulation or modern insulation scheme for
copper conductors and modified core dimension having minimum core loss with
mineral insulating oil as the cooling medium.
6.7 The transformer shall be forced oil cooled by means of circulating oil pump and
radiator. The cooler (radiator) shall be air cooled by means of a motor blower set.
(Rev. ‘0’) dt. 30.07.2008
The pump, the radiator and the cooler blower shall be mounted on the
transformer body. The ratings of these equipment should be adequate to ensure
cooling of the transformer to the desired standards. The exhaust of the cooler
blower shall preferably be arranged through the roof of the locomotive. There is
a depression of 12 mm (WG) inside the loco. The design of cooling equipment
should take this into account.
6.8 The transformer tank shall be provided with drain plug and filling valves, filtering
valves, sampling valve, oil flow relay, conservator tank with Silica gel breather, oil
temperature indicator with contacts for operating in a audible alarm in the
drivers cabs, oil level gauge and explosion vent. Necessary valves in between
the transformer tanks and cooler shall be provided.
6.9 The transformer shall also be supplied and provided with necessary
accessories for its protection like current transformer along with over
current relay for over current protection and air flow & oil flow relays for
detecting the failure of ventilation & oil circulation.
6.10 Various terminals from the traction winding shall be so located as to

enable shortest interconnections between the transformer and the rectifier
cubicles.
6.11 The construction of the transformer shall be such as to keep the weight of
the transformer as low as possible while meeting adequately the severe
requirements of traction duty such as rapid load variation, vibration, short
circuits etc. Tenderer shall also furnish the design calculation of MPH as well as
radiator with motor blower set in view of higher thermal losses due to provision
of hotel load winding. Tenderer shall also adopt Aluminium tubes & fins design
radiator in place of conventional design to keep the total weight of the
transformer with cooling equipments similar to the existing 5400 KVA
transformer.
6.12 Technical data to be furnished by the tenderer with the offer is given in Annexure-
A.
6.13 Additional technical data to be furnished by the successful tenderer is given in

Annexure-B.
6.14 The technical data of the smoothing reactor, rectifier, tap changer & traction motor
in use are given in Annexure-C.
7.0 Tests
7.1 Transformer Including Hotel Load Winding
The Type and Routine Tests shall be carried out on the transformer as per Table-
1 below which also stipulates the category of the tests and the clause to which
the reference is to be made.
(Rev. ‘0’) dt. 30.07.2008
TABLE-1
TESTS Clause or sub-clause

Type Routine Investigation
Preliminary checks 7.1.1 7.1.1 -
Measurement of winding resistance 7.1.2 7.1.2 -
Measurement of voltage ratios 7.1.3 7.1.3 -
Measurement of no-load primary current 7.1.4 7.1.4 -
and losses
Measurement of impedance voltages 7.1.5 7.1.5 -
Measurement of load losses 7.1.6 7.1.6 -
Determination of total losses 7.17 - -
Temperature Rise 7.1.8 - -
Dielectric :
- full wave impulse voltage withstand 7.1.9 - -
- induced voltage withstand 7.1.10 7.1.10 -
- separate source voltage withstand 7.1.11 7.1.11 -
Measurement of IR of windings 7.1.12 7.1.12 -

Pressure and Leakage test on Tank 7.1.13 7.1.13 -
Measurement of weight 7.1.14 - -
Vibration & Shock 7.1.15 -
Short circuit test 7.1.16 -
7.1.1 Preliminary Checks (IEC 60310- Clause 18)
Visual inspection and identification of the circuit diagram, terminal meetings,

polarities & particulars on the rating plate shall be carried out.
7.1.2 Measurement of Winding Resistance (IEC 60310- Clause 19)
Resistance of each winding shall be measured with direct current at ambient

temperature and the values thus obtained corrected to 75 deg.C.
7.1.3 Measurement of Voltage Ratio (IEC 60310- Clause 20)
Voltage ratio shall be measured between Auto windings at different taps and both
secondary windings. Voltage ratio shall also be measured between HV winding
& Auxiliary winding, & Hotel load winding .
The measured values shall be with-in ± 0.5% of the design values.
7.1.4 Measurement of No load primary current & losses (IEC 60310 - Clause 21)
(Rev. ‘0’) dt. 30.07.2008
No load primary current and losses shall be measured with 50 Hz sinusoidal

voltage applied to high voltage winding. However, this measurement can also be
carried out by energising Auxiliary/hotel load winding. No load current and
losses for the primary winding shall be measured at 17.5 KV – 27.5 KV in steps
of 2.5 KV.
7.1.5 Measurement of Impedance Voltage (IEC 60310- Clause 22)
Impedance voltage between each pair of the windings shall be measured at rated
frequency using approximately sinusoidal voltage supply.
The short circuit impedance between primary winding and the traction
windings shall be with-in ± 15% of the design value.
7.1.6 Measurement of Load Losses (IEC 60310- Clause 23)
Load losses between HV winding and traction windings, Auxiliary winding and
Hotel load winding shall be measured and corrected to 75 deg.C. The corrected
losses shall not exceed the guaranteed values specified by manufacturer.
7.1.7 Determination of total losses of transformer (IEC 60310 -Clause 24)
The total losses of the transformer at reference temperature of 75 deg. C shall be

computed as under:-
(a) Load losses of HV to all Traction windings

(b) Load losses of HV to Auxiliary winding
(c) Load losses of HV to Hotel load winding
(d) No load losses
The total transformer losses will be the sum of (a), (b), (c) & (d) above.
The total transformer losses shall not exceed the limit specified by the
manufacturer.
7.1.8 Temperature rise test (IEC 60310- Clause 25)
This test on the transformer shall be carried out by short circuit method to
determine temperature rise of oil, average temperature of air at the blower
entrance, average temperature of air at cooler exit, average temperature of oil at
transformer exit, average temperature of oil at cooler exit. For this,
Thermocouples shall be provided at locations as under:
(Rev. ‘0’) dt. 30.07.2008
• Top oil pocket - One

• Air entrance to the blower – One
• Air exit under the cooler – one
• Oil exit from the transformer – One
• Oil inlet to the transformer - One
• Oil containers – Three, located at about 3 m from the transformer
7.1.8.1 Oil Temperature Rise
For this test, with the auxiliary winding and hotel load winding left open circuited,
the Secondary windings shall be short circuited and primary windings energized
such as to feed losses in the transformer determined in clause 7.1.7 above.
These losses fed in the transformer shall be maintained till oil temperature
stabilizes. The oil temperature measured and temperature rise calculated.
The temperature rise of oil shall not exceed 45 deg.C.
7.1.8.2 Winding Temperature Rise
• HV Winding
For this test, the Secondary windings shall be short circuited and supply given to
HV winding so as to feed 240 Amps. in HV winding for a duration of 60 min. At
the end of 60 min., blowers shall be switched off and hot resistance of the HV
winding measured.
• Traction Windings
For this test, with blowers on, series connected traction winding shall be short
circuited and supply given to HV winding to feed 5400 Amps. in traction windings
for a duration of 60 min. The blowers shall be switched off and hot resistance of
the traction windings measured.
• Auxiliary Winding
For this test, with blowers switched off, the auxiliary winding shall be short
circuited and supply applied to HV winding with 325.3 Amps in Aux. winding for a
duration of 60 minute at the end of which hot resistance of the winding shall be
measured.
• Hotel Load Winding
For this test with blowers switched off, the hotel load winding shall be short
circuited and supply applied to HV winding with 1333.3 Amps. in hotel load
winding for a duration of 60 minutes, at the end of which hot resistance of the
hotel load winding shall be measured.
7.1.8.3 Overloading Temperature Rise Test:

(Rev. ‘0’) dt. 30.07.2008
Overloading test as per para 4(viii),(ix) & (x) shall be carried out on the
winding with maximum temperature rise.
7.1.9 Impulse voltage withstand test (IEC 60310- Clause 26.3)
The HV winding shall be subjected to impulse voltage test of 150 KVp, 1.2/50
micro second wave.
The winding shall withstand the test voltage.
7.1.10 Induced Voltage Withstand Test (IEC 60310- Clause 26.1)
All traction and hotel load windings shall be shorted & connected to tank and
earth. Auxiliary winding shall be energised such as to induce 60 KV voltage in
HV winding.
The winding shall withstand the test voltage.
7.1.11 Separate source voltage withstand test (IEC 60310-Clause 26.2 )
Single phase 50 Hz, separate source voltage of amplitude as given below shall
be applied for 1 minute between each winding to be tested and all other windings
connected together to tank and earth:-
(i) primary winding and all other windings to earth 10 KV

(ii) Traction winding to all other windings and earth 10 KV
(iii) Auxiliary winding to all other windings and earth 6 KV
(iv) Hotel load winding to all other windings and earth 6 KV
The windings shall with stand the test voltage.
7.1.12 Measurement of IR value (IEC 60310 -Clause -)
Measurement of IR value of individual windings to Tank and Earth and between

windings shall be carried out at room temperature. The values obtained after 60
seconds shall be corrected to 30 deg. C. For HV winding & all other windings
5/2.5 kV megger shall be used.
7.1.13 Pressure & Leakage Test on Tank (IEC 60310 -Clause -)
Pressure test on the transformer tank shall be carried out at a pressure of 14.2
PSI over the normal head of oil for a period of 24 hours. There shall be no oil
leakage from the tank.
There shall not be any leakage during or at the end of the test.
7.1.14 Measurement of weight (IEC 60310 -Clause -)
The weight of the Transformer filled with mineral oil shall be measured.
(Rev. ‘0’) dt. 30.07.2008
7.1.15 Vibration & Shock
Vibration & Shock test on the transformer shall be carried out as per
IEC:61373(latest).
7.1.16 Short Circuit Test
Short Circuit test shall be carried out as per IEC:60310. The test voltage shall
be 27.5 KV and both the secondary traction windings are to be subjected to short
circuit test with two shots each out of which first short is to be applied at the highest
voltage tap No. 32 and the second shot on 18th tap.
Variation in % impedance before & after the short-circuit test shall not
differ more than ±1%. After the test, the transformer to be removed from the tank
and no observable deformation, movement or slackening of any winding,
insulation over clamping devices should be revealed.
8.0 Technical Documents to be supplied by the Supplier :

The following documents shall be supplied by the supplier as a part of
the contract :
i) Type test reports – 5 copies

ii) Routine test reports along with each set – 5 copies
iii) Maintenance manual – 1 copy per unit
iv) Detailed drawings – 6 copies
v) Supplier should submit detailed drawings and technical source of sub-
supplier for approval before manufacturing of prototype sample.
vi) Design data calculation and drawings of transformer submitted by the
supplier during design approval
9.0 Quality Assurance
Quality assurance should be as per ISO:9000 quality management system.
NOTE:- 1. The firm should emboss following data in their product :

- Make
- Year and month of manufacturing
- Sl. No.
- Trade mark, if any
- Drg. No.
- Order No.
(Rev. ‘0’) dt. 30.07.2008
2. Standard fasteners shall be used from CLW approved sources.
3. Quality Assurance Plan for the Transformer shall be

prepared covering various aspects given below &
submit to RDSO :
3.1 The QAP to be submitted by the vendor in duplicate (along with

the application form for registration) shall cover the following
aspects –
a) Organisational Chart, clearly indicating the Quality Control Set- up.
b) Qualification of key personnel and the officials deployed in Quality

Control Cell.
c) Process Flow Chart indicating process of manufacture for an individual

product or for a family of products if the process is same.
d) Quality Assurance System – Inspection & Testing Plan. This shall

cover the following :-
• Incoming material
• Process control
• Product control
• System control
• Gauging scheme – in the format for each operation gauges should be
mentioned, if used.
e) Stage inspection detailing inspection procedure, inspection

parameters, method of testing/test procedure including sample sizes
for destructive and non- destructive testing etc
f) Calibration scheme and status of calibration of test

equipment.
The generalized format for covering the information under (d & e) should
be as below :-
Subject/ Sample Parameters Mode of Acceptance Rejection

Product/ Size & its for inspection/ limits/ details
Process Frequency inspection equipment Criteria Repro-
of . used /specified cessed/
inspection Value Scraped
g) QAP covering all the information as asked above under item ‘a’ to ‘f’ must
be given in the form of single document indicating name of the firm and
page no. ‘x’ of ‘y’ on each page. Each page should be signed by QC in-
(Rev. ‘0’) dt. 30.07.2008
charge. The approved QAP must be a controlled document and a quality

record of ISO:9000 quality control system of the vendor. A certificate to
this effect shall be provided along with the QAP by the vendor.
3.2 The QAP shall be provisionally approved by the officer nominated for
capability assessment and final approval shall be given by concerned
Director/ Jt. Director
3.3 The QAP shall be submitted in duplicate. One copy, after final approval
will be given back to the vendor.
(Rev. ‘0’) dt. 30.07.2008
Annexure-A
TECTNICAL DATA TO BE SUPPLIED WITH THE OFFER
TRANSFORMER
1. Make
2. Type
3. Standard
4. Primary Voltage (kV)
i) Nominal
ii) Maximum
iii) Minimum
5. Continuous rating at 22.5 kV
Winding Primary Traction Auxiliary Hotel or Auxiliary +

(secondary) load Hotel load
No. of windings
No load voltage (V)
Current (A)
Capacity (kVA)
6. Percentage impedance voltage at

rated traction winding current of
2700 A each at all tap positions from
1 to 32 tap with
i) One winding shorted

ii) Both windings shorted
7. Percentage impedance voltage of
- Auxilliary winding (%)

- Hotel load winding (%)
or
- Tertiary Winding(Auxiliary + Hotel load)
8. No load magnetization current
i) at 22.5 kV (A)
ii) at 27.5 kV (A)
9. Flux density in the core

(Rev. ‘0’) dt. 30.07.2008
i) at 22.5 kV (Wb/m²)
ii) at 27.5 kV (Wb/m²)
10. Current density at rated current
i) Primary (A/mm²)
ii) Traction (Secondary) (A/mm²)
iii) Auxiliary (A/mm²)
iv) Hotel load (A/mm²)
or
v) Auxiliary + Hotel load (A/mm²)
11. Transformer losses At 22.5kV At 27.5kV
Core (kW)
Copper (kW)
Total (kW)
12. Transformer overall efficiency
i) at 22.5 kV (%)
ii) at 27.5 kV (%)
13. Permissible and designed temperature rise separately
(i) Oil ( °C )
(ii) Winding ( °C )
(By resistance method)
14. Type of cooling and cooling medium
15. Class of insulation
a) On conductors
b) Cooling medium
16. (i) Material of insulation on the conductor
(ii) Material of the cooling medium (Mineral oil/Silicons fluid)
(iii) Thermal and electrical characteristics of conductor insulation.
(iv) Thermal and electrical characteristics of cooling medium.
17. Dielectric levels Primary Traction Auxiliary Hotel load or Aux.+hotel load
(a) Induced voltage

withstand (kV)
(b) Separate source

(Rev. ‘0’) dt. 30.07.2008
voltage withstand (kV)
(c) Impulse voltage

withstand (Kvp)
18. Construction
i) Type of core : Core type/Shell type

ii) Type of winding : Concentric coils/sandwich coils
iii) type of winding
construction (single coil or more coils in series/parallel)
- Primary
- Secondary
- Auxiliary
- Hotel load
19. Weight of transformer and oil
i) Without cooling equipment

ii) 'with cooling equipment
20. Overall dimensions of the transformer
i) Without cooling equipment
ii) With cooling equipment (Attach drawings)
21. Oil
i) Weight
ii) Volume
22. Data on additional equipment
i) oil circulating pump
a) Motor - Make
- Type
- Rating
- Insulation class
- Weight
b) Pump - Make
- Type
- Speed
- Quantity & head
- Weight
ii) Fluid circulating blower
a) Motor - Make
(Rev. ‘0’) dt. 30.07.2008
- Type
- Rating (kW)
- Voltage (V)
- Current (A)
- Speed (RPM)
- Insulation class
- Weight
b) Pump - Make
- Type
- Speed (RPM) (Max)
- Air Quantity (m3/hr) & head (mm WG)
- Weight (kg)
iii) Radiator - Make

- Type
- Rating (kW)
iv) Current transformer
- Type
- Make
- Ratio
- Burden (VA)
- Accuracy class
- Insulation class
v) Overload relay
- Type
- Make
- Ratio
- Burden
- Accuracy class
- Setting value
vi) Oil flow relay
- Type
- Make
- Range
- Setting
vii) Oil temperature indicator
- Type
- Make
- Range
- Setting
viii) Silicagel
(Rev. ‘0’) dt. 30.07.2008
- Type
- Make
23. The following drawings/curves/calculations shall be submitted by the tenderer

along with the offer :
Outline and general arrangement drawing of the transformer,
24. The contractor shall also furnish detailed drawings showing core arrangement,
winding/coil arrangement, insulation arrangement, cross sectional drawings, rating
plate etc. for transformer.
25. Overload Vs. duration curve of the transformer with sample calculations for the
same.
(Rev. ‘0’) dt. 30.07.2008
ANNEXURE-B
ADDITIONAL DATA TO BE SUBMITTED BY THE CONTRACTOR
TECHNICAL DATA OF MAIN TRANSFORMER
1. Rating:
1.1 Primary Volts Amps. kVA
1.2 Traction (Secondary) Volts Amps. kVA
1.3 Auxiliary Volts Amps. kVA
1.4 Hotel load Volts Amps. kVA
1.5 Magnetising current(%)
1.6 Core losses:
- 22.5 kV
- 27.5 kV
Primary Traction Auxiliary Hotel load or Aux.
(Secondary) hotel load
_______ _______ _______ _______ _______
1.7 Copper losses
1.8 Total losses
1.9 Resistance (%)
1.10 Reactance (%)
1.11 Current density
2. Winding details Primary Traction Auxiliary Hotel or Aux. +

(Secondary) load hotel load
______ __________ ______ ______ ______
2.1 Total No. of turns

2.2 No. of windings
2.3 No. of coils
2.4 Sections per coil
2.5 Turns per coil
2.6 Turns per layer
2.7 No. of layers
2.8 Size of conductor
2.9 Total sectional area
2.10 No. of parallel conductors.
2.11 Mean length of
winding (mm)
2.12 Weight of copper wire(kg)
2.13 Coil dia (inner)
2.14 Coil dia (outer)
2.15 Depth of winding (radial)
(Rev. ‘0’) dt. 30.07.2008
2.16 Height of section

2.17 Conductor insulation
2.18 Winding method
2.19 Inter connection of sections
2.20 Inter connection of coils
2.21 Clearance between HV&LV
Primary Traction Auxiliary Hotel or Aux. +

(Secondary) load hotel load
_____ _______ ______ _____ _______
3. Magnetic Circuit Details
3.1 Grade (silicon sheet steel)
3.2 Thickness (mm)
3.3 Space Factor (%)
3.4 Core constructional

arrangement (2 or 3 limb)
3.5 Sectional area

- Gross ( cm²)
- Nett ( cm²)
3.6 Flux density at :
- 22.5 kV (wb/m²)
- 27.5 kV (wb/m²)
3.7 Volt/turn at :
- 22.5 Kv
- 25.5 kV
3.8 Mean core length (mm)
3.9 Dimensions of
windows (mm)
3.10 Outer dimensions
4. Ancillary Data
4.1 Operating pressure

of explosion vent
4.2 HV and LV bushing

Specification
4.3 Weight (kg)

i) Core and coils
ii) Tank and fittings
(Rev. ‘0’) dt. 30.07.2008
iii) Fluid (lit.)

iv) Cooler and pump
v) Fluid
vi) Total weight of
Transformer block
5. Calculations
5.1 Temperature rise calculations for

rated load and overloads.
5.2 Reactance calculations for different

windings for arriving at designed value.
5.3 Calculations for thermal and mechanical

effects under 3 second short circuit.
5.4 Calculations for arriving at the regulation

characteristics of the transformer alongwith
the regulation curve (dc voltage vs dc current)
(Rev. ‘0’) dt. 30.07.2008
ANNEXURE-C
TECHNICAL DATA OF EXISTING EQUIPMENT IN USE

1. Tap Changer
(i) Type : No-32
(ii) No. of taps : 32
(iii) Rated Voltage : 25 KV 50 Hz
(iv) Rated current : 400 A
(v) Weight of the tap changer without oil : 481 Kg
(vi) Oil capacity : 75 Lit.
2. RECTIFIER
(i) Input nominal voltage : 1000 V rms
(II) System of connections of diodes : Bridge
(iii) Surge voltage protection level : 3.7 KV
(iv) Direct current rating of rectifier with all : 4050 A - 5 min.
Bridges healthy with blower : 3300 A - 10 min.
: 3150 A – Cont.
(v) DC rating of rectifier bridge with all
Bridges healthy without blower motor : 2700 Amps.
for minimum period of 30 min.
(vi) Design short circuit capacity :36.65 KA( Asymmetric)
corresponding to traction motor for 100 ms during
flashover. Continuous loading of
2700 A with
asymmetric factor of 1.6
(vii) Design short circuit capacity : 60 KA for 10 ms

Corresponding to short circuit continuous loading
Within rectifier before smoothing reactor of 2700 A.
2. SMOOTHING REACTOR
(I) Make : CLW

(ii) Type : SL-30
(iii) Number : 2
(iv) Circuit rated voltage : 1270 V
(v) Continuous rating : 1350 A per limb
(vii) One hour rating : 1640 A per limb
(vii) Inductance : 3.35 ± 0.3 mH
across each coil
(viii) Insulation : 180 ºC
temp. index
(Rev. ‘0’) dt. 30.07.2008
(ix) Ripple factor : 28.1%
3. TRACTION MOTOR
(i) Continuous rating : 750 V, 900 A, 895 rpm, 850 h.p.

(ii) One hour rating : 750V, 960 A, 877 rpm, 905 h.p.
(iii) Permanent shunting : 5%
(iv) Field strength
- Max. : 95%
- Min. : 40%
- Intermediate : Three field shunting
(v) Max. Starting current : 1350 A for 2 minutes
of the Motor
(vi) Short time rating : 1200 A for 10 minutes
(viii) Motor Resistance 115ºC
and inductance value:
- Armature : 0.01283 Ohms 1.2 mH
- Main Field : 0.0122 Ohms 2.2 mH
- Interpole : 0.0093 Ohms 0.6 mH

STR 6670 KVA Oil Filled Transformer For AC Locomotive

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RDSO//2008/EL/SPEC/0072

Page 1 of 27 Issued on 08.08.2008

SPECIFICATION NO. RDSO/2008/EL/SPEC/0072 (Rev. ‘0’) dt. 30.07.2008

6670 KVA TRANSFORMER with HOTEL LOAD

FOR WAP4, 25 KV AC LOCOMOTIVE

SPECIFICATION NO. RDSO/2008/EL/SPEC/0072 (Rev. ‘0’)

RESEARCH DESIGNS AND STANDARDS ORGANISATION

3.0 Climate & Environment Conditions

5.0 Technical Data

6.0 General Design and Constructional aspects

8.0 Technical Documents to be supplied by the Supplier

9.0 Quality Assurance

Annexure - A – (TECTNICAL DATA TO BE SUPPLIED WITH THE OFFER)

Annexure – B (ADDITIONAL DATA TO BE SUBMITTED BY THE CONTRACTOR)

Annexure – C (TECHNICAL DATA OF EXISTING EQUIPMENTS IN USE)

Specification for 5400 KVA Transformer with

3.0 Climate & Environment Conditions

Atmospheric Metallic surface temperature under Sun: 75o C max. and in

level of 102 mm above rail level.

• IEC-60310 - Rules for traction transformers and

5.0 TECHNICAL DATA

(ii) Minimum Primary voltage for

(iii) Minimum voltage for functioning

(v) No. of traction winding - Two

(vi) System of connection - One winding for each

(b) Rated continuous current of each - 2700 A(approx.)

(c) Apparent continuous power - 2700 x 1000

(d) Total continuous apparent - 2 x 2700 KVA

(e) Percentage Impedance - 10% ± variation as per

(f) The No load voltages at different taps from 0 to 32 notch

Tap Position Secondary voltage at traction

(viii) Emergency Operation - In the event of failure of

(ix) Percentage overload - 60% for two minutes followed

(x) Special duty

(xi) Auxiliary Winding

a) No. of windings - One

b) Rated voltage at - 830 V

c) Continuous rated - 270 KVA

e) Type of Loads - Single phase to three phase

a) No. of windings - One

b) Rated voltage at - 750 V

c) Continuous rated - 1000 KVA

e) Type of Loads - Single phase to three phase

a) No. of windings - One

b) Rated voltage at - 750 V

c) Continuous rated - 1270 KVA

e) Type of Loads - Single phase to three phase

(xiv) Rated primary power of - (5400 + 270 + 1000) KVA

(xv) Cooling - Oil forced air forced

(xvi) Temperature rise limits - For class ‘H’ insulation for

(xvii) Insulation - Class ‘H’ with mineral insulating

(xviii) Core - Latest core design with minimum core

(xix) Cooling medium - Inhibited Transformer Oil

6.0 General Design and Constructional aspects:

d) Hotel load winding for meeting hotel load power

e) A tank filled with mineral oil as coolant provided with

6.10 Various terminals from the traction winding shall be so located as to

6.13 Additional technical data to be furnished by the successful tenderer is given in

7.1 Transformer Including Hotel Load Winding